Changing my fuel pump, any tips? - Ford Powerstroke Diesel Forum
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Old 01-11-2008, 04:42 PM
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Changing my fuel pump, any tips?

I've not done this yet but seems pretty straight forward. Are there any tips or things I should watch out for? Any other things that I should replace while I'm in there?
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Old 01-11-2008, 09:09 PM
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If it's like my '96 that was supposed to be fleet maintained, have a foot or so of fuel line handy. There are a few short lines that replacing wouldn't hurt being changed while you are at it.
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Old 01-12-2008, 05:29 AM
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Just did this a few weeks ago on my 97. What a pain in the azz. Drain the fuel out of the fuel filter housing then take that out. There is a big nut on the back of the pump that has to come off IIRC it's a 1 1/4". You can just barely get a boxed end wrench in between the nut and the turbo pedestal, but it can be done. Also when lifting the pump off the valley there is a plunger underneath that will slip out and slide down into the motor so be careful. When putting the fuel filter housing back on i would go ahead and disconnect the fuel heater wire that's on the drivers side of the housing. There are 2 black plugs with wires connected, it's the top one. (The bottom one is your water in fuel sensor.) If you don't disconnect the wire more than likely messing with the housing it will short out and blow your #22 fuse and your truck will not start. Good Luck!!
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Old 01-12-2008, 05:34 AM
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The big banjo bolt on the back of the pump is an 1 1/4" depending on how the flats of the bolt are positioned you might have to bend the end of the wrench a lil to get it on there and make sure to replace the crush washers there too. Ford sells the 3 little lines for little or nothing and regular fuel line won't last long down there. As far as the tappet for the fuel pump the best thing to do is loosen all the bolts on the fuel pump and then rotate the motor until the fuel pump pops up so you know the lobe on the cam is at top dead center, that way the tappet cannot fall into the motor if it falls out of the pump. And make sure to use some assembly lube on the end of the new tappet before stabbing it back together.
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Old 01-13-2008, 07:15 AM
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Are there o-rings where the big banjo bolt connects to the fuel pump? Do they need to be replaced ('96 PSD)?
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Old 01-13-2008, 07:36 AM
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No, they are flat copper washers just like those that connect a brake line to the caliper.
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Old 01-13-2008, 04:32 PM
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Thanks for the replys, I got it done in just under 3 hours. That banjo bolt sure was a pain in the arse! I couldn't believe how much crap was in the fuel filter housing! And I would bet nearly a 1/2 cup of water and goo. But was way easier than I was anticipating.
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Old 01-14-2008, 09:09 AM
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I just replaced mine a few weeks ago and suprisingly, it went very well. I was concerned about getting the crush washers positioned as I started the banjo bold. On the first attempt the forward crush washer slid out of position. For the second try I got some sewing thread from the wife and looped it through the the front washer, slid the banjo bolt in, and then carefully pullled the thread out. I already had the fuel bowl out so replacing the pump took less than an hour.
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Old 01-14-2008, 09:51 AM
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Ok I feel like an idiot now becuase for some reason I felt that I couldnt get the banjo bolt off while the pump was still installed, so I ended up bending up the fuel line trying to get it out attached to the pump, then the turbo Had to come out to put a new metal line in. Wish I would have know all this first!!!
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Old 01-14-2008, 04:01 PM
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Anyone know where to get new crush washers?

Or do you just re-use the old ones?
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